Fastener Member for Affixation to a Structure in an Orthopedic Device and Method for Securing the Same

ABSTRACT

A fastener member for mechanical affixation to a structure includes a base having first and second sides, a plurality of fastening elements integrally formed and extending from a first side of the base, and at least one affixation element extending from the second side of the base and arranged to mechanically affix to an attachment opening of a structure. A system includes a structure and a fastener member for mechanical affixation to the structure. A method includes affixing the fastener member to a structure.

TECHNICAL FIELD

The present disclosure relates to a fastener member for mechanical affixation to a structure, and more particularly to a fastener member including a plurality of fastener elements extending from a side and affixation means for selectively and removably engaging a structure, such as a molded article or frame element in an orthopedic device.

BACKGROUND

In orthopedic devices, textile and/or foam liners are typically attached to frame elements of the device by using hook and loop fastener systems. The liners are provided in part to protect the user from the frame elements which may be rigid or semi-rigid, whereas the liners provide a comfortable interface between the user and the frame element.

It is common practice to use adhesives, ultrasonic welding, or other means to attach pieces of hook material to the frame element, and the liner includes or incorporates hook engageable material or pieces (i.e., loop material) to attach to the hook material pieces on the frame element. It is often found, however, that the shear forces applied to the adhesives on the hook material pieces, coupled with the temperature fluctuations and humidity inherent with orthopedic devices, causes the hook material pieces to slide and migrate over a period of use. This causes problems for the user, as the liner now improperly covers the frame elements, and pressure points may emerge at the edges of the frame element.

The hook material pieces may likewise be used for engaging a strap loop which retains the orthopedic device on the anatomy of the user. Again, adhesive applied hook material pieces tend to migrate which displaces the location of the strap and may lead to a deterioration of the efficacy in securing the device on the user.

In the past, injection molded hook integrally molded onto the frame element has been used to prevent the hook elements sliding and coming lose from the frame element. This is done in such a manner that an insert for the hook elements is placed into an injection molding tool for the frame element and an integrally-formed field of hooks is created during molding or manufacturing of the frame element so the hook is molded directly into the plastic of the frame element. Obviously, this method eliminates the need for adhesively applying the aforementioned hook material pieces and reduces the step of later applying hook material pieces later in the fabrication of an orthopedic device.

While injection molding the hook elements directly onto frame element is effective, it suffers from the drawback that many orthopedic devices do not lend themselves to including integrally molded hook elements. Knee brace shells are commonly post formed onto a user's leg mold after the frame elements are formed by injection molding rendered in a flat configuration. Because the frame elements may be subsequently contoured after the frame element itself is formed, integrally molded hook elements may become damaged during the post-forming and customization process. Due to the inherent differences in shape of each user, the integrally molded hook elements may be at a less favorable location after the frame element has been formed. Known methods for integrally molding hook elements lack flexibility for later modification in location and limit the degree by which frame elements may be customized for an individual user.

SUMMARY

Embodiments according to the disclosure are directed to a fastener member and method for using the same for mechanical affixation to a molded article or frame element, and particularly to a fastener member including a plurality of fastener elements extending from a side and means for selectively and removably engaging a molded article or frame element.

The fastener member embodiments are arranged to mechanically and selectively engage a frame element at post-formation of the frame element. By mechanical engagement, the arrangement of the fastener element obviates the need to adhesively secure hook material pieces to the frame element or integrally form hook elements at the formation of the frame element. By selective engagement, a clinician can place the fastener at many locations suitable for a desired application, such as securing to a liner or engaging a strap. From the arrangement of the fastener element, migration of the hook element is eliminated and damage of hook elements during post-forming of the frame elements is prevented.

The fastener member is arranged for having an affixation element that is releasably affixed to a structure, such that the affixation element can be quickly fixed to the structure without machining, molding or applying adhesive, and can be easily detached from the structure without being damaged.

The fastener member embodiments may retrofit on existing orthopedic devices having frame elements defining suitable openings capable of interengaging various means for affixing the fastener members to the frame element to connect brace components, such as liners, padding, and straps, to the frame element.

A fastener member for mechanical affixation to a structure includes a base having first and second sides, a plurality of fastening elements integrally formed and extending from a first side of the base, and at least one affixation element extending from the second side of the base and arranged to mechanically affix to an attachment opening of a structure.

The at least one affixation element includes a stem protruding from the base and a head extending from the stem. The head may have a length greater than a width of the stem. A plurality of fastening elements may include first and second rows of hook elements, and the hooks of each of the first and second rows extend in opposing directions, respectively.

According to a variation, the base may have a substantially flat back side. The base may be flexible and arranged to accommodate a shape of the structure upon which the fastener member is affixed.

The at least one affixation element may define first and second resiliently flexible side legs spaced apart by gaps on opposed sides of a center leg. A head may form flange segments extending from both of the side legs and have a mirror image of one another. A periphery of the base may be elongate and have rounded edges.

The at least one affixation element may include first and second affixation elements protruding from the base. Each of the first and second affixation elements may define a resiliently flexible side leg carrying a head having a sloped face and extending to a flange. The sloped faces may be arranged in opposed directions relative to the length of the base.

A system has a frame element and a fastener member for mechanical affixation to the frame element. The fastener member is arranged to mechanically affix to an attachment opening of the frame element. The frame element may include an opening through which the at least one affixation element extends. The at least one affixation element has a head defining a dimension extending longer than a width of the opening. The frame element may include at least one rib protruding from a peripheral wall defining the opening. The at least one affixation element is arranged secured against the peripheral wall. A thickness of the frame element at the opening is generally the same as a length of a stem extending from the base and carrying the head. The system may use any of the fastener members and variations of the frame element described herein.

A method for affixing a fastener member to a structure includes providing an attachment opening on the structure, attaching the fastener member to the structure. The fastener member includes a base having first and second sides, a plurality of fastening elements extending from a first side of the base, and an affixation element extending from the second side of the base. The method further includes affixing the affixation element to the structure about the attachment opening.

A thickness of the frame element at the opening is generally the same as a length of a stem extending from the base and carrying the head. The head may have a length greater than a width of the stem. The method may include using any of the fastener elements described herein and attaching the same to the attachment opening.

In another embodiment, the fastener member may be permanently secured to a structure. According to one variation, the fastener member is secured within a recess formed by a structure, and a fastener retains the fastener member within the recess. The recess can prevent rotation or shifting of the fastener member relative to the structure, whereas the fastener keeps the fastener member from pulling away from the structure.

The fastener member may be formed from a material different from the structure, either more rigid or more flexible. For example, the structure may be constructed from carbon fiber or aluminum, and may be more or less rigid than the fastener member. While it may not be feasible to construct the fastener member from certain types of structure, but it may be desirable to have a strong fastener member rather than conventional hook material in known hook and loop systems and this is achieved by providing an injected molded fastener member that can be selectively secured to a structure.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood regarding the following description, appended claims, and accompanying drawings.

FIG. 1 is a perspective view showing a first embodiment of a fastener member.

FIG. 2 is a schematic sectional rear view showing affixation of the fastener member of FIG. 1 onto a frame element.

FIG. 3 is a schematic sectional front view showing affixation of the fastener member of FIG. 1 onto a frame element.

FIG. 4 is an exemplary perspective view of a prior art fastener element configuration.

FIG. 5 is a perspective view showing a second embodiment of a fastener member.

FIG. 6 is a schematic sectional rear view showing affixation of the fastener member of FIG. 5 onto a frame element.

FIG. 7 is a schematic sectional front view showing affixation of the fastener member of FIG. 5 onto a frame element.

FIG. 8 is a cross-sectional view taken along line VIII-VIII in FIG. 7.

FIG. 9 is a schematic view of FIG. 8 without the fastener member.

FIG. 10 is a perspective view showing a third embodiment of a fastener member.

FIG. 11 is a schematic sectional rear view showing affixation of the fastener member of FIG. 10 onto a frame element.

FIG. 12 is a schematic sectional front view showing affixation of the fastener member of FIG. 10 onto a frame element.

FIG. 13 is a cross-sectional view taken along line XIII-XIII in FIG. 12.

FIG. 14 is a schematic view showing a configuration of a set of fastener members securing a strap to a frame element.

FIG. 15 is a schematic view showing the set of fastener members securing to a strap as in FIG. 14 on a variation of a frame element.

FIG. 16 is a schematic view showing a fastener member secured to a frame element.

The drawing figures are not necessarily drawn to scale, but instead are drawn to provide a better understanding of the components, and are not intended to be limiting in scope, but rather to provide exemplary illustrations. The figures illustrate exemplary embodiments of a frame element in an orthopedic device, and in no way limit the structures or configurations of a fastener member and structure for receiving the fastener member according to the present disclosure.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Under a first embodiment according to the disclosure, FIG. 1 depicts a fastener member 10 having a base 11 carrying a plurality of fastener elements 22 along a front side 12. A backside 14 of the base 11 includes an affixation element 16 arranged for securing to a structure. The affixation element 16 has a stem 18 defining a first end extending perpendicularly from the base 11 and a head 20 on a second end of the stem 18.

According to an embodiment, the backside 14 has a substantially flat contour. The base 11 may be substantially rigid or may be flexible to accommodate a shape of a frame member.

While the stem 18 is preferably cylindrical in shape, the head 20 preferably is not round and extends in length greater than a width or diameter of the stem 18. The head may have a variety of different shapes. The head 20 is a non-round component extending from opposed sides of the stem 18. Alternatively, the head has a diameter greater than the diameter of the stem.

The fastener member may be made from various materials. The body may be made of polymeric materials, such as polyvinyl chloride, polypropylene, or other engineering plastics. The base, affixation element, and the fastener elements may be formed as a unitary structure, or alternatively the affixation or the fastener elements may be secured to the base. The fastener member may be trimmable so the base periphery can be modified according to particular usage or a location along the frame element.

The fastener member may be rendered or formed in a substantially flexible condition or may be rendered or formed into a rigid condition, depending on the intended application and desired durability of the fastener member.

The fastener elements may be arranged in the prior art example in FIG. 4. The fastener elements 22 are a plurality of hooks 32 arranged in alternating rows and integrally formed with the base 12 from the backside 14. The fastener element may be configured in a variety of ways, such as various shapes, materials, arrangements, numbers of elements; the hook elements may comprise structure capable of separable attaching to a loop material.

While the fastener member 10 is depicted as having a generally square or rectangular profile, the base periphery 26 may take on a variety of shapes and sizes. The base periphery is not limited to the shape and size depicted, and may be suitably adapted depending on the type of structure it is affixed to and to which the hook elements should engage. The fastener member is not limited to a single affixation element, but may include multiple affixation elements depending on the size and shape of the fastener element and the structure upon which it is affixed.

While affixation elements are described in combination with this embodiment, the fastener members described may be attached to a structure in a variety of ways. The affixation element may be removed or provided in combination with ultrasonic welding, riveting, insert molding, or an adhesive to assure that the fastener member is securely retained on the structure. The structure, such as the frame element, may include a recessed portion into which the fastener member is secured so that either the affixation element or the base other than the fastener elements protrude from a surface of the structure to minimize exposure of the fastener member and contribute to a streamlined configuration.

In reference to FIGS. 2 and 3, the fastener member 10 is shown as attached to a structure in a molded article or frame element 24 in an orthopedic device. An example of a frame element 24 is found in U.S. Pat. No. 7,198,610, granted on Apr. 3, 2007, and incorporated by reference. Examples of padding, spacer elements, straps and other components capable of securing to the fastener elements may also be found in U.S. Pat. No. 7,198,610.

The frame element 24 has a plurality of attachment openings 28 and corresponding peripheral walls 30 formed from the structure and delimiting the openings. In the example in FIGS. 2 and 3, the attachment openings take on the shape of elongate slots formed from the frame element. The width of the attachment openings is smaller than the length of the head of the fastener member and generally matches the diameter or width of the stem 18, although the length of the attachment openings may be significantly longer than the length of the head.

FIG. 2 shows how the width and length of the attachment openings is defined, whereas FIG. 5 shows how the width, length and height of the affixation element may be defined however the height of the stem in the fastener member 10 is defined between its first and second ends. FIG. 5 also shows how the length of the base can be defined. FIG. 8 shows how the thickness of the frame element may be defined.

As shown, the fastener member 10 is secured to the frame element 24 by securing the head 20 against a first surface 34 of the frame element beyond the peripheral walls 30 of the attachment openings 28. The backside 14 of the fastener member 10 is arranged adjacent to a second surface 36 of the frame element 24 due to the stem 18 having a height generally corresponding to the thickness of the walls 30 to assure that the backside 14 of the fastener member 10 is snugly secured against the second surface 36 of the frame element 24. The front side 12 of the fastener member 10 is arranged to readily expose the fastener elements 22.

When selecting where to install the fastener member 10, the clinician may choose among any of the openings adapted to receive the stem. The head is inserted through the opening such that the length of the head is generally parallel with the length of the opening. Once the correct position along the opening is selected, the clinician rotates the fastener member such that the length of the head is generally perpendicular to the length of the openings.

The fastener member may be adapted to slide relative to the walls of the opening, or alternatively snugly fit against the frame element without movement once placed into the desired location. Alternatively, the frame element may include recesses along either of the first or second frame surfaces at predetermined locations to receive the head once rotated in a secure placement.

In referring to the embodiment of FIG. 5, another fastener member 110 is provided having a variation of an affixation element 116. The fastener member 110 has a base 111 carrying a plurality of fastener elements 122 along a front side 112. A backside 114 of the base 111 includes an affixation element 116 arranged for securing to a structure.

The affixation element 116 has a pair of resiliently flexible side legs 118 spaced apart by gaps 134 on opposed sides of a center leg 132. The head 120 extends from both of the side legs 118 and generally take on a mirror image of each other. Each head 120 includes a flange 130 that protrudes from the stem 118. The periphery of the head 120 has sloped edges 121 outside of the portion adjacent the center leg 132.

As shown in FIGS. 5 and 7, the base periphery 126 is generally elongate and has rounded edges. According to this embodiment, the fastener member is adapted to provide greater surface in a length direction of the fastener member for exposing the fastener elements 122 from the front side 112.

When installed on the frame element 124, the fastener member 110 is secured to the frame element 124 by securing the flanges 130 of the heads 120 within an attachment opening 128 so as not to extend beyond a surface of the frame element. The head 120 of the affixation element 116 generally corresponds in shape to the periphery of the attachment opening 128. The backside 114 of the fastener member 110 is arranged adjacent to a second surface 146 of the frame element 124 due to the side legs 118 snugly securing against the frame element 124. The front side 112 of the fastener member 110 is arranged to readily expose the fastener elements 122.

As shown in FIG. 8, the height of the affixation element 116 corresponds to the thickness 142 of the frame element 124. As better depicted in FIG. 9, the frame element 124 defines ribs 138A, 138B defined between upper and lower wall portions defining the attachment opening 128. When the affixation element 116 is inserted into the attachment opening 128 with some degree of force, the sloped edges 121 of the head 120 slide against the ribs 138A, 138B and the side legs 118 resiliently bend toward the center leg 132. Once the flanges 130 pass past the ribs 138A, 138B, the flanges 130 return to their initial state such that the flanges 130 extend over the ribs 138A, 138B to lock or snap-fit the fastener member relative to the frame element 124. Further movement of the affixation element 116 is prevented since the height of the affixation element 116 generally corresponds to the thickness 142 of the frame element 124.

In referring to FIG. 10, another embodiment of a fastener member 210 has opposed affixation elements 216A, 216B protruding from a base 211 carrying a plurality of fastener elements 222 along a front side 212. Each of the affixation elements 216A, 216B defines a resilient flexible side leg 218 carrying a head 220 having a sloped face 221 and extending to a flange 230. The sloped faces 221 are arranged in opposed directions of the length of the base 211. As with the other fastener members, the base has a periphery 226 that is both adaptable in shape and size.

According the embodiment of FIG. 10 and depicted in FIGS. 11-13, the fastener member 210 is secured against the wall portions 236 of a pair of attachment openings 228A, 228B. The side legs 218 are arranged to flexibly extend into the attachment openings 228A, 228B along the wall portions 236 and snap-fit against the wall portions such that the flanges 230 extend over a surface of the frame element and the side legs 216 are resiliently urged against the wall portions 230.

As exemplified in FIG. 14, a set of fastener members 318, 320 may be arranged on a frame element 312 in a variety of configurations, and a strut 314 may be connected to other brace components. In this example, the frame element 312 defines a plurality of horizontally oriented attachment openings 324, 326, 328 on opposed sides, and received the fastener members 320, 322. A strap 316 has opposed end portions that engage the fastener members 318, 320.

The fastener members 320, 322 may be arranged under the embodiments described. As depicted in FIG. 14, the fastener members 318, 320 that generally correspond to the fastener member 10. At least h the fastener member 318 includes an affixation element 322 adapted to slide relative to the frame element, although delimited by ends of the attachment opening thereby permitting some adjustability while when a user wears the brace. A pad having some frictional component may be on the strap which prevents migration of the strap despite the ability of the fastener members to travel. Tension of the strap on the user may likewise limit movement of the fastener member. A clinician can select among one of the attachment openings 324, 326, 328 arranged according to height of the frame element 312.

FIG. 14 exemplifies how a recess 338 may be formed on a structure, as in the frame element 314, and corresponds in shape with the fastener member 320 to retain the fastener member 320 in place, and also to minimize or eliminate clearance of the base other than the fastener elements from a surface of the frame element. The fastener member 320 may be attached to the frame element 314 in any manner described.

As shown, the fastener members 318, 320 are placed on opposed surfaces of the frame element. The fastener members are not limited to this arrangement, and may be likewise placed along the same surface. Multiple fastener members may be attached along the same attachment opening to lengthen the area that includes fastener elements if it is found the given length of an individual fastener element is insufficient. The fastener members may be supplemented with an adhesive besides the mechanical coupling, and may also be in combination with adhesively applied hook material pieces in a retrofit condition.

In referring to FIG. 15, an alternative frame element 314 defines a plurality of vertically oriented attachment openings 330, 332 arranged at opposed sides of the frame element 314. The frame element is not limited to the arrangement of vertically or horizontally oriented attachment openings on opposed sides of the frame element. Attachment openings can be in any orientation and at any location on the frame element to receive a fastener member.

The frame element 314 may include recesses 334 into which an affixation element 322 may be located. The recesses 334 may be arranged in a manner which permits the affixation element 322 and hence the corresponding fastener member 322 may rotate or linearly travel within a certain range. The frame element 314 may include stop protrusions 336 which likewise limit travel of the fastener member by stopping rotational and linear movement of the fastener member.

The frame element 314 allows for the strap 316 to adjust in height, and rotate according to movement of the user. In a knee brace, the strap may be allowed to slide upwards and downwards while the leg moves between extension and flexion, especially if the brace includes some frictional contact with the user such as a friction component on a liner. The motion of the fastener members may reduce shear forces exerted on the skin of the user.

Despite the embodiments described, attachment of the fastener member on a frame element may be arranged so the fastener member is fixed in place, or is movable as discussed above with the embodiments of FIGS. 14 and 15.

In another embodiment exemplified by FIG. 16, the fastener member 12 may be permanently secured to a structure 352. According to one variation, the fastener member 12 is secured within a recess 354 formed by the structure 352, and a fastener 350, such as a rivet, retains the fastener member within the recess 354. An opening 356 may be provided within the structure to accommodate the fastener 350. The fastener member 12 may be sized and configured to snugly fit within the recess 354. The recess 354 can prevent rotation or shifting of the fastener member 12 relative to the structure 352, whereas the fastener 350 keeps the fastener member 12 from pulling away from the structure 352. Alternatively, the fastener member 12 may be secured to the structure 352 by an adhesive.

The fastener member may be formed from a material different from the structure, either more rigid, more flexible or the same. For example, the structure may be constructed from carbon fiber or aluminum and is essentially more rigid than the fastener member. It may not be feasible to construct the fastener member from the structure, but it may be desirable to have a strong fastener member rather than conventional hook material in known hook and loop systems where the hooks are constructed from nylon or similar material substantially dissimilar from the structure.

The fastener members may be configured to retrofit existing frame elements in existing orthopedic devices having frame elements defining suitable openings capable of interengaging various means for affixing the fastener members to the frame element. The frame element can receive another type of orthopedic device feature, for example liners, padding, and straps, carrying suitable loop element or other material or structure capable of securely engaging with fastener elements on the fastener member.

While the structure is described with an orthopedic device, the structure may comprise any form of structure for any type of device requiring a fastener member under the embodiments described.

The skilled artisan will recognize the interchangeability of various features from different embodiments. Besides the variations described, other known equivalents for each feature can be mixed and matched by one of ordinary skill in this art to construct fastener members and structural element for attachment of the fastener members under principles of the present disclosure.

Although the embodiments have been disclosed in certain exemplary embodiments and examples, it therefore will be understood by those skilled in the art that the present invention extends beyond the disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents. It is intended that the scope of the present invention disclosed should not be limited by the disclosed embodiments described above. 

1. A fastener member for mechanical affixation to a structure, comprising: a base having first and second sides; a plurality of fastening elements integrally formed and extending from a first side of the base; at least one affixation element extending from the second side of the base and arranged to mechanically affix to an attachment opening of a structure.
 2. The fastener member of claim 1, wherein the at least one affixation element includes a stem protruding from the base and a head extending from the stem.
 3. The fastener member of claim 2, wherein the head has a length greater than a width of the stem.
 4. The fastener member of claim 1, wherein the plurality of fastening elements include first and second rows of hook elements, the hooks of each of said first and second rows extending in opposing directions, respectively.
 5. The fastener member of claim 1, wherein the base has a substantially flat back side.
 6. The fastener member of claim 1, wherein the base is flexible and arranged to accommodate a shape of the structure upon which the fastener member is affixed.
 7. The fastener member of claim 1, wherein the at least one affixation element defines first and second resiliently flexible side legs spaced apart by gaps on opposed sides of a center leg.
 8. The fastener member of claim 7, wherein a head forms flange segments extending from both of the side legs and form a mirror image of one another.
 9. The fastener member of claim 8, wherein a periphery of the base is generally elongate and has rounded edges.
 10. The fastener member of claim 1, wherein the at least one affixation element includes first and second affixation elements protruding from the base, each of the first and second affixation elements defining a resiliently flexible side leg carrying a head having a sloped face and extending to a flange.
 11. The fastener member of claim 1, wherein the sloped faces are arranged in opposed directions relative to the length of the base.
 12. A system having a frame element and a fastener member for mechanical affixation to the frame element, the fastener member including: a base having first and second sides; a plurality of fastening elements extending from a first side of the base; at least one affixation element extending from the second side of the base and arranged to mechanically affix to an attachment opening of the frame element.
 13. The system of claim 12, wherein the frame element includes an opening through which the at least one affixation element extends, the at least one affixation element having a head defining a dimension extending longer than a width of the opening.
 14. The system of claim 12, wherein the frame element includes at least one rib protruding from a peripheral wall defining the opening, the at least one affixation element arranged secured against the peripheral wall.
 15. The system of claim 12, wherein a thickness of the frame element at the opening is generally the same as a length of a stem extending from the base and carrying the head.
 16. A method for affixing a fastener member to a structure, comprising the steps of: providing an attachment opening on the structure; attaching the fastener member to the structure, the fastener member including a base having first and second sides, a plurality of fastening elements extending from a first side of the base, and an affixation element extending from the second side of the base; affixing the affixation element to the structure about the attachment opening.
 17. The method of claim 16, wherein a thickness of the frame element at the opening is generally the same as a length of a stem extending from the base and carrying the head.
 18. The method of claim 16, wherein the head has a length greater than a width of the stem. 